Building structure



Patented Feb. 8, 1938 UNITED STATES PATENT OFFICE 2,107,523 BUILDING STRUCTURE Elbert B. Coe, Warner's, N. Y.

Application November 15, 1935, Serial No. 49,993

9 Claims.

This invention relates to certain new and useful improvements in building structure and to the method of forming the same.-

It is a well established fact'that with the conventionally constructed buildings and heating systems, when the walls of the building are not directly hea-ted, a large percentage of the heat of the human body is lost by radiation during cold weather to the relatively cold building walls with the result that the air in the rooms must be maintained at a relatively high temperature to render said rooms comfortable.

The main object of this invention is to provide a building structure adapted for a residence, store or the like in which the walls are peculiarly adapted for use in connection with heating, ventilating and air conditioning the interior of the building, and which will thereby be maintained in cold weather at a higher degree of temperature than the normal temperature of the human body so that the loss of body temperature through radiation to the walls is substantially eliminated.

Further objects of the invention are to provide a structure of the above mentioned class which is particularly adapted for modern style of architecture, and which is simple, economical and durable in construction.

In carrying out the above mentioned objects, I have provided a building structure composed of concrete and steel wherein the walls and floors are provided with suitable air passages or ducts adapted to be connected with a heater and air conditioning unit. These passages or ducts are so arranged that hot conditioned air leaving the heating unit will be evenly distributed throughout the interior of the floors and walls of the building and conveyed thereby to the interior of the rooms and thence returned to the air conditioning and heating units. This not only provides for very low velocities of air movement but also insures warm walls, floors and ceilings in the winter. Furthermore, the arrangement of the air ducts in the walls and floors of the building are such that in the summer a natural draft may be created therethrough by which cool air will be taken from the basement of the building and circulatedthrough the walls and rooms for cooling and ventilating purposes.

A further object of the invention is to provide dead air spaces in the outside walls of the building for insulating the warm and cold' air ducts from each other and from the cold passing inwardly through the outer portion of the walls by conductivity.

A still further object of the invention resides in providing means whereby the heated air may be circulated through the window structures and thus not only eliminate the cold draft usually present at windows, but also provides for as many windows as may be desired without materially 5 decreasing the total area of the air passages in the walls of the building.

' Another object of the invention resides in providing a structure of the above mentioned class wherein the walls may be formed of two diiferent l0 grades or classes of materials cast simultaneously. Other objects and advantages pertaining to my novel building structure and to the method of forming the same will more fully appear from the following description taken in connection with the 15 accompanying drawings in which:

Figure 1 is a vertical sectional view of a building structure with portions thereof broken away and embodying the various features of this invention.

Figure 2 is a detail horizontal sectional view ing the same in operative relation with a pair of vertical wall columns.

Figure 6 is a longitudinal sectional view taken on line 6-6, Figure 5, illustrating an'intermediate portion of the lower end of the form broken away.

Figures 7 and 8 are horizontal sectional views taken respectively on lines 'l--! and 8-8, Figure 5.

Figure 9 is a detail sectional view taken on line 99, Figure 6.

Figure 10 is a detail vertical sectional view illustrating my novel window frame structure and the relation thereof with the air ducts taken substantially in the plane of the line Ill-ll, Figure 3.

Figure 11 is a side elevation of the furnace indicatedin Figure 1 and illustrates the same connected with a suitable air conditioning apparatus. In Figure l of the drawings, I have illustrated a building structure comprising outer side walls i,

inner side walls or partitions 2, floors 3, ceilings 4 and a roof structure 5, all of which are illustrated as being'composed of concrete, plaster or the like, which may be reinforced in the usual manner by suitable posts or columns, crossbeams, joist and the like,formed preferably of steel or other suitable material. v v a In constructing the outer side walls, i preferably use outer and inner side form members I!) and I I as shown in Figure 3 and a multiplicity of air duct form members l2 as shown in Figure 5.

\ The outer and inner side form members l and H are each composed of intermediate form sections l3 composed of sheet metal and which are preferably of convenient size for handling; Each section I3 comprises a rectangular base l4 preferably about :two feet square although this size may be altered if desired. This base is provided with marginal flanges !5 arranged to extend outwardly from one side of the base portion. The flanges l5 are providedwith longitudinally spaced apertures I6 which, when the forms are arranged side by side, are adapted to align with corresponding apertures in the flanges of the adjacent form for the reception of tie bolts H which releasably clamp the form sections to each other.

The intermediate wall forms I3 are joined at the corners of the building by outer and inner corner forms l9 and 20 respectively and where necessary, as illustrated in connection with the inner wall in Figure 3, a section as 2| is interposed between the corner sections I9 or 20 and the intermediate wall sections l3 to position these intermediate sections in proper cooperative relation with the opposite wall sections and with the upright columns of the wall. These corner sections l9 and 20 and the sections 2| are each provided with marginal flanges i9, 20' and 2| respectively which correspond in size and arrangement to the marginal flanges I5 of the intermediate sections l3 whereby the sections may be joined to each other by the bolts ll. The corner sections I9 and 20 and the sections-2| are each of substantially the same height as the intermediate sections I3 whiie the length of these sections is less than that of the intermediate sections. 1

' These upright columns for the outer walls of the building are in two forms; one as 23, is particularly adapted to be used at the corner of the walls,.while other columns as 24 are adapted to be used intermediate the corners of the walls and are spaced from the corner columns 23 and from each other a uniform distance depending upon the length of the intermediate wall form sections I3. For instance, if the upright columns are spaced a distance of two feet from each other, the length of the intermediate wall formsections l3 are likewise two feet so that said form sections and columns maybe readily mounted in cooperative relation during the forming of the walls in a manner which will hereinafter be more fully explained.

The intermediate columns 24 are, in this instance, formed of two channel members 26 as shown in Figures 2 and 3. These channels are referably formed from steel plates although structural channels may be used. The channels are mounted back to back in slightly spaced relation. Each of the channel members 26 is provided with a plurality of longitudinally spaced apertures 21 formed in the transverse portion intermediate the longitudinal sides thereof and are spaced apart a distance substantially equal to the height of the intermediate form sections 03. The openings 21 in each channel member are adapted to align with corresponding openings in the other channel member of a respective column and have mounted therein a U-shaped tie clip 28 which, as shown in Figures 3 and 4, extend transversely of the column members through the openings. The

opposed sides of each U-shaped clip 28 are profixedly secure the clamping sleeves to the columns. These sleeves and clips also function .to

maintain the column channels in fixed predeterv minedspaced relation relative to each other.

Each of the sleeves 29 is provided with an internal threaded openingfor the reception of a clamping bolt 30 provided for'the wall form'sections l3. I9; and 2L. Theseclamping bolts 30 are preferably permanently connected withthe corresponding side form section and for'this pur-- pose, are each provided with a coliar 3| fixedly secured thereto in any suitable manner in a slightly spaced relation to the head of the screw. These screws extend through corresponding openings provided in the wall section with the collar 3| positioned against the outer face of the base of the section in retaining clips or straps 32 secured by spot welding or other means to the adjacent portion of the form section. These clamping bolts are preferably mounted in the form section adjacent an end thereof and the outer form-sections are preferably secured to the upright columns in reverse order to the inner form sections, as shown in Figure 3, so that the abutting ends of the outer form sections will be arranged in staggered relation relative to'the columns to that of the inner form sections to thereby produce a'more rigid form structure for receiving the plastic material forming the walls during the pouring thereof.

The corner columns 23 are preferably composed of four upright members, two box shaped members 34 and two channel shaped members 35. The box shaped members are arranged in diagonal relation with the corners of the building while the channel shaped members 35 are positioned intermediate the box shaped members as shown in Figure 3. The outer box shaped member 34 and the adjacent channel shaped members 35 are each provided" with longitudinally spaced apertures similar tothe' aperture 21 in the intermediate channel members 26. These apertures in each channelmemberar'e arranged in aligned relation with corresponding apertures in the other channel members for the reception of an L=shaped tie clip 3'1. These tie clips 31 are adapted to extend intermediate two adjacent wall columns. The frame has secured thereto in any suitable manner, two sets of air duct core blocks 42 and 43 which are arranged to extend downwardiy below the connection thereof with the frame in substantially a-vertical plane a distance considerably greater than the height of the wall form sections l3. .These sets of core blocks 42 and 43 are arranged in transverse spaced relation with each other. One of the sets as 42 in this instance, is comprised of three members arranged in parallel spaced relation, while the other set 43 is composed of two members also arranged in parallel spaced relation with each other and which are preferably of less thickness than the block of the other set 42 but of greater width so that the total cross sectional area of the core members of each set are substantially equal to each other. Interposed betweenthe two sets of core members 42 and 43' are a plurality of, in this instance three, vertically disposed core plates 44 arranged in parallel spaced relation with each other substantially midway between the two sets of core blocks 42 and 43, as illustrated in Figure 8. The core plates 44 are of substantially the same width as the core blocks 42 and are secured at their upper ends to the frame 40 in any suitable manner to extend downwardly in alignment with corresponding block members 42.

At the rear or opposite side of the core blocks 43 are positioned a plurality of, in this instance .four, core plates 45 which are secured at their upper ends tothe frame 40 and extend downwardly therefrom in longitudinal parallel spaced relation with each other. At the rear or outside of the plates 45 is positioned a core or separating plate 45 also secured at its upper end to the frame 40. The plate 46 as shown in Figure 8, is substantially a U-shaped member in cross section with the longitudinal side portions 46 of the legs thereof extended outwardly from the legs in substantially parallel relation with the transverse portion of the plate and these side portions 46 are arranged one at either side of the set of core blocks 43 in substantially the vertical plane passing through the center of said blocks. The vertical lengths of the plates 44, 45, and 46 are substantially equal to or slightly greater than the height of the Wall form sections l3 and slightly less than that of the core blocks 42 and 43. The frame 40 is provided with, in this instance 8,

-wheels 43 arranged four at either side thereof and which are journaled upon suitable axles 49 secured to the. cross pieces 4|. The wheels 48 are flanged members and are so arranged that when the frame is mounted in operative relation with the columns 24 or one of the columns 24 and a corner column 23, said wheels will rotatably engage flanges of the column channels as shown in Figure '7 for guilding the frame 40, and, therefore, the core members 42, 43, 44, 45, and 48 during their vertical movement.

The frame 46 is also provided with means as a cable 50 connected with the upper end thereof to which the cable of a suitable derrick may be attached whereby the frame may be moved vertically relative to the columns to properly position the core. members when forming the wall. The

axles 49 for the wheels 48 are preferably mounted in elongated horizontally disposed slots 52 provided in the frame 40 as shown in Figure 9, and latch members 53 are pivotally secured to the frame for releasably maintaining the axles in the outer end of the slots in which position of the relative to the frame to bring the wheels out of holding engagement with the channel members.

In constructing the outer walls of the building the end columns 23 and the intermediate columns 24 are first mounted in any suitable manner upon a foundation wall as 54, Figure 1, with the intermediate columns 24 arranged in equal spaced relation from each other and from the end columns 23, the spacing of these column members being equal to the lengths of the intermediate side wall form sections I3.

A horizontal row of side wall form sections l3, I9, 20, and 2| are then secured to the lower end portions of the columns adjacent the foundation wall 54 by screw threading the screws 30 into corresponding sleeves 29 after which the sections may be secured to each other by clamping bolts l1 and the sections brought into proper aligned relation with each other and in suitable ,spaced relation to the upright columns by the screw threading of the screws 3%] into the corresponding sleeves 29 to a greater or less degree. A conduit form unit I2 is then mounted in each space between adjacent column members with the core 'blocks 42 and 43 resting upon the also properly positions the plates 44, 45, and 46 for forming corresponding dead air spaces.

When a frame 40 is operatively connected with -a. pair of column members, the core plate 48 is positioned intermediate the core plates 45 and the outer wall form sections l3 and the longi tudinal side portions 46 of these plates are so arranged, that they will extend into the adjacent channel member of the adjacent column and terminate in close proximity to the transverse wall of said channel member so as to form a separating plate between the outer portion of the wall and the inner portion thereof, whereby the outer portion of the wall may be formed of one class of materials such as concrete, while the inner portion of the wall may be formed of a different class or grade of materialsuch as gypsum plaster which may be poured simultaneously with the cement if desired.

After the side forms and core forms have thus been positioned, a course of plastic wall material or materials about the thickness of the height of the outer and inner side forms I3 is first poured and as soon as the wall material such as concrete and plaster has solidified sufiicienily, the wall forms and the core frames are moved upwardly and secured in properrelation with the portion of the wall previously poured after which a second course of wall material is poured in the same manner as the first course. After the second course of wall material has sufficiently solidified to maintain its form, the form and core members are again readjusted and a third course of wall material is poured and so on until the side walls are completed.

It will now be observed by referring more particularly to Figures 1 and 3 that each outside wall formed by pouring plasticwall material between the side forms IE! and If and around the core blocks and plates of the air duct form members l2 comprises three vertically disposed side portions 55, 56 and 5! which are separated byair spaces and connected together by transversely disposed bond portions 58, 59, 56', and 59' formed integral with the side portions. The bond portions 58' and 59' cooperate with the side portions for encasing the colunms 24 and the clamping members 28 and 29 associated therewith. The bond portions 58 and 59 are arranged intermediate the bond portions58' and 59 as shown and cooperate with the latter bond portions and side portions 55, 56, and 51 to form two series of air ducts 60 and 6|. The ducts of these series correspond, of course, in cross sectional area to the cross sectional area of the core blocks 43 and 44 respectively and as will be understood, extend from within a short distance of the foundation wall 54 upwardly and form an inner and an outer series of air ducts respectively. The inner series of air ducts 6| are connected by respective ports 63 with a common manifold 64 which, in turn, is connected by feed pipes 65 with a suitable hot air furnace 66. The manifold 64 may, as indicated in Figure 1, be a horizontally disposed pipe ,or conduit mounted within the basement of the building to extend along each side wall.

However, it is obvious that these manifolds may be cast integral with the side walls if desired or the air ducts 6| may be connected with each other in any other suitable manner whereby the air heated in the furnace 66 will be evenly distributed to the inner series of,air'ducts 6| to pass upwardly therethrough.

Likewise, the outer series of air ducts 60 are connected by ports 68 with a suitable manifold 69, common to all of the ducts of the outer series and which, in turn, is connected by return pipes Ill with a suitable air conditioning apparatus 1|, which may be associated with the heater 66 or these return pipes may be connected directly with the heater in the usual manner.

It will also be observed by referring to Figure 3 that the outer walls are each provided with three groups of dead air spaces, 12, I3, and 14. The dead air spaces 12 are formed bythe plates 44 in the intermediate side portion 56 of the wall.

The dead air spaces 13 are'formed by the core plates 45 in the outer side portion of the wall in close proximity to the outer series of air ducts and the third group of air spaces 14 is produced by the core plate 46 and is arranged intermediate the group of dead air spaces I3 and the outside of the walls.

It will thus be seen that the outer series of air ducts 60 are insulated from the outer surface of the wall by the dead air spaces 13 and 14, while the inner series of air ducts 6| are insulated from the outer series of ducts by the dead air spaces 12 so that the relatively low degree of temperature in the outer series of air ducts will not be carried by conductivity through the intermediate side portion 56 while the high degree of temperature maintained in the inner series of air ducts will be prevented from escaping by conductivity to the outer series of air ducts. It will, therefore, be seen that hot air passing upwardly through the inner series of air ducts 6| will maintain the inner surface of the side walls at a relatively high degree of temperature without excessive loss of heat while relatively cool return air passing downwardly through the outer series of air ducts 60 will be prevented from being excessively chilled due to the insulation afforded by the two outer series of dead air spaces 13 and 14 and whatever cold passing through the outside wall portion 55 by conductivity reaches the outer air ducts 60 will be carried downwardly by the return current of air to the heater 66 where the air is warmed before passing upwardly through the warm air ducts 6|.

It will be readily understood that during the construction of the outer walls, the inner walls or partitions 2, floors 3, and ceilings 4 may also be formed. The inner walls or partitions 2 like the outer walls, are preferably provided with two series of air ducts I6 and H which may be formed simultaneously with the construction of the walls by use of two sets of core blocks as 42 mounted upon a suitable carriage or frame as 40. It will thus be seen that the inner walls or partitions like the outer walls, comprise 3 vertical side portions, an intermediate portion 56' and two side portions 51. These air conduits I6 and 11 are preferably of substantially the same size and formation and are maintained in communication with the inner series of air ducts 6| provided in the outside walls by means of suitable passages or conduits 18 formed intermediate the floors 3 and ceilings 4 in any well known manner which it is believed to be unnecessary to further describe in this application.

The vertical hot air ducts 6|, l6, and 11 are provided with ports or restricted passages 80 formed in the side portions 51 of the inner walls 2 and the side portion 51 of the outer walls I adjacent the ceiling of the rooms defined by these Walls by suitable core members 82, Figure 3, inserted into suitable apertures provided in the inner form sections Likewise, the

outer series of air ducts 60 formed in the outer Walls are maintained in communication with the rooms of the building near the lower portion thereof by means of restricted air ports-or passages 8| formed in the intermediate and inner side portions 56 and 51 and the bond portions 59 by core members 83.

It will now be readily understood that hot air passing from the furnace 66 into the manifold 64 will pass from said manifold upwardly through the inner or hot air ducts 6| in the outer Walls and will also pass through the air ducts 18 provided intermediate the floors 3 and ceilings 4 and thence upwardly through the air ducts 16 and 11 provided in the inner walls and through ports 80 into the upper portions of the rooms defined by said walls adjacent the ceiling. This warm air then circulates downwardly through the rooms and as it becomes cooled, it will pass outwardly through the ports 8| into the outer series of air ducts 60 and thence back to the furnace 66. The air passing from the inner or hot air ducts 6| into the conduits 18 provided in the upper floor of the building may pass outwardly through suitable apertures provided in the floor into the interior of the attic and thence out through ports 8| into the outer series of air ducts 66.

Furthermore, if desired, the roof of the building may be provided with a series of air ducts 83 in communication with corresponding air ducts 65. Ports or restricted passages 84 are shown for maintaining the ducts 83 in communication with the attic.

The roof is also provided with one or more ventilators 85, in communication with the roof ducts 83 so that when the outer walls of the building are subjected to a relatively high degree of temperature as that produced during the summer season, the heat passing by conductivity through the outer portions of the side walls into the outer series of ducts 60 will heat the air creating an up-draft which, when the dampers as 81 provided in the return pipes 10 are closed,

\ will draw air from the lower portions of the rooms through the ports 8| and carry the same upwardly out through the ventilator while cool air from the basement will be drawn upwardly through the heater 66 and pipe 65 to the inner series of air ducts 6| and thence through the ports into the upper portion of the rooms and thereby maintain the interior of the building at a relatively cool degree of temperature by natural ventilation. It is to be understood that when the system is functioning as above indicated, an opening is provided in the wall of the basement as by opening a window while a damper as 1| provided in the air conditioning apparatus II is opened to provide a complete circulation passage which is formed by the air conditioning apparatus H, heater 66, conduit 65, ports 63, air ducts 6|, 19, 16, and ll and ports 80 through which the cool air in the basement may readily pass to the interior of the rooms.

I have provided a novel form of window structure which comprises in providing a rectangular frame as 88 for each window composed preferably of sheet metal having the upper and lower sides thereof provided with apertures 89 and 90 correspending in cross sectional area to the ducts 60 and 6| respectively and which are adapted to align with said ducts when the frame is mounted in the outer side walls. These frames are each provided with three panes of glass as indicated by broken lines at 9|, 92, and 93, Figure 3, arranged one at either side of the openings 89 and 90 and one intermediate said openings to form .separate passages aligned with respective air ducts intercepted by the window frame. These passages through each window provide means whereby air will circulate through the ducts intercepted by the windows in the normal manner; W

that is, hot air passing upwardly through the inner air ducts 6| will pass outwardly through the corresponding Window passage between the panes of glass 92 and 93 and then through openings 80 into the interior of the room, while the return air passing downwardly through the outer series of ducts 60 will pass through the passage formed by the panes of glass 9| and 92, and thence in the conventional manner to manifold 69 and furnace 66.

While I have shown the core blocks 42 and 43 as each being solid unitary members, I do not wish to be limited to such construction, as core blocks of various other forms and constructions may readily be used in lieu of those shown. This is particularly true where it is desired to maintain the opposite sides of the air ducts 60 and 6! formed thereby straight and parallel instead of in non-parallel relation as may be the case where the core blocks are given suflicient draft to enable them to be easily withdrawn from the wall material. For example, the core blocks may be provided with a suitable coating of rubber, or they may boot a collapsible nature whereby the cross sectional area of the blocks may be reduced before withdrawing the blocks from the casting position.

Furthermore, in place of the dead air spaces 12, 13, and 14, I may utilize standard insulating material provided in sheet form, or I may use such insulating material in conjunction with these air spaces, in which case, the air spaces would be of such form and size as to readily cooperate with the insulating material.

It will thus be readily understood that although 1; have shown and particularly described the preferred embodiment oi my invention, I do not wish to be limited to the exact construction shown or to the method of construction disclosed herein as various changes therein may be made without departing from the spirit of the invention as set forth in the appended claims.

I claim:

1. A hollow wall construction for a building comprising three vertical side portions separated V by air spaces and connected at spaced intervals by vertically disposed bond portions which divide the air spaces into two series of vertically extending air ducts, said wall being provided with two series of horizontally disposed restricted air. passages, one series of air'passages for eachseries of air ducts whereby one series of air passages connect the interior of the building with one of the series of vertically extending air ducts and the other series of air passages connect the interior of the building with the other series of vertically extending air ducts.

2. A structure as in claim 1 having air conveying means for operatively connecting each series of air duets with a hot air furnace.

3. A device as in claim 1 having air conveying means for operatively connecting one of said'series of air ducts with the air intake of a hot air furnace and separate air conveying means for operatively connecting the other series of air duets with the air exhaust of said hot air furnace.

4. A device as in claim 1 wherein one of the vertical side portions is provided with a series of vertically extending dead air passages. j

5. A device as in claim 1 wherein the wall is provided with two series of dead air spaces arranged one at either side of one of the series of air ducts.

6. A hollow wall construction for a building comprising three vertical side portions separated by air spaces and connected at spaced intervals by vertically disposed bond portions which divide the air spaces into two series of vertically extending air ducts, bond portions associated with one series of air ducts being arranged in staggered relation with bond portions associated with the other series of air ducts, said wall being provided with a series of horizontally disposed restricted air passages extending through one of the side portions thereof for connecting the adjacent series of air ducts with the interior of the building, and a second series of horizontally disposed restricted air passages extending through two adjacent side portions and the bond portions interposed therebetween for connecting the other series of air ducts with the interior of the building.

7. A device as in claim 6 having separate air conveying means for connecting one of the series of air duets with the air intake of a hot air furnace and the other series of said air ducts with the air exhaust of said hot air furnace.

8. A building structure having a side wall thereof defining upper and lower rooms and provided with two series of air ducts in communication respectively with the upper and lower portions of said rooms, a window frame mounted in said wall and intercepting certain of the ducts of both series, said frame being provided with means including three window panes arranged in parallel spaced relation with each other for providing a pair of air passages therethrough for maintaining the corresponding ducts of said series in communication with each other, and air conveying means for connecting one of said series of air duets with the feed passage of a heating unit and the other series of duets with the return passage of said heating unit.

5 9. 1 building structure having outer and inner side walls and floor and ceiling structures defining a plurality of rooms, each of said side walls being provided with two series of air ducts arranged in transverse spaced reiation with each 10 other, air ducts in the floor and ceiling structures maintaining each series of air ducts in the inner side wall in communication with the inner adja- ELBERT H.\GOE. 

